Bobbin winder, method and yarn package produced thereby

ABSTRACT

In an apparatus for winding yarn on a bobbin, the yarn is distributed by a flyer which rotates about an axis that is disposed at an angle to the bobbin axis. The bobbin is rotated in a direction opposite to the direction of rotation of the flyer. The flyer moves axially relatively to the bobbin in a single direction throughout the winding period. The resulting package contains yarn that runs continuously in and out between the inner periphery and the outer periphery of the yarn package enhancing subsequent package dyeing operations.

United States Patent [191 Kawamura et a1.

[ BOBBIN WINDER, METHOD AND YARN PACKAGE PRODUCED THEREBY Inventors:Sadao Kawamura,

Kyoto; Hideo Matsuno, Osaka, both of J apan Toray Engineering Co., Ltd.,Osaka, Japan Filed: Mar.'18, 1971 1 Appl. No.2 125,780

Assignee:

US. Cl 242/18, 57/1, 242/2, 242/26.5, 242/159 Int. Cl... B65h 54/04,B65h 55/04, B65h 57/00 Field of Search 57/67, 70, 72, 71, .57/34 R,75,1'15,l18,156,116, 35; 242/26.1, 26.2, 26.3, 27, 159, 168, 174, 178,

[56] References Cited UNITED STATES PATENTS 3,393,502 7/1968' Reecler57/75 X 2,451,352 10/1948 Nou-Touron 57/116 1 June 26, 1973 2,301,71111/1942 Seem et a1. 242/178 3,334,842 8/1967 Pillar et al.

3,342,437 9/1967 Massey 242/178 FOREIGN PATENTS OR APPLICATIONS 211,1834/1957 Australia 57/75 641,708 5/1962 Canada 57/75 530,700 12/1921France 57/67 800,555 8/1958 Great Britain 57/75 Primary Examiner-D0naldE. Watkins Attorney-Paul & Paul [57] ABSTRACT 9 Claims, 16 DrawingFigures rmmcnmzsm 3.741.469-

sum 1 or a l 1 g PRIOR ART "1 b ERsinB 3/) E PRIOR ART BY H I DEOMATSUNO ATTORNEYS.

' SADAO KAWAMURA' PMENTEUJUI 2 6 I915 I INVENTORS. SADAO KAWAMURA IHIDEO MATSUNO ATTORNEYS.

GENERAL FIELD OF THE INVENTION This invention relates to an apparatusfor winding yarn on a bobbin, to a method for performing such winding,and to a package having a novel arrangement of yarn thereon.

In normal bobbin winding, the yarn is reciprocated relatively back andforth along the axis of the bobbin and the yarn is laid upon the bobbinor upon yarn previously laid upon the bobbin, in successive layerscommencing at a relatively small radius along the surface of the bobbinand gradually building up to the final relatively large radiuscorresponding to the outer periphery of the yarn package. Accordingly,when the yarn is disposed in such successive layers, barriers arecreated which tend to prevent the flow of dye either radially inwardlyor radially outwardly through the yarn in a sub sequent package dyeingprocess. This, of course, impedes the effectiveness of dyeing andsometimes results in non-uniformity of dye intensity in various portionsof yarn on the package. Also, dye flow tends to become channeled withsuch an arrangement, increasing the problems of non-uniformity ofdyeing.

Also, such previous processes involve rather rapid axial reciprocationof yarn with respect to the bobbin in addition to rapid rotation of thebobbin and rapid rotation of the'flyer, with attendant mechanicaldifficulties. i

The dyeing of yarn in a coiled state, or as a cheese or corn is wellknown and has merit, since it is not necessary' to form coils inpreparing the yarnfor dyeing.

However, package dyeing is subject to the drawback that dyeing of yarntends to be non-uniform. Also, the step of feeding the dyed yarndirectly from the packages to looms or knitting machines is difficultbecause conventional winding techniques have not been matched withpackage dyeing.

The necessary conditions with respect to the package for package dyeingare (A) minimum overlapping of yarns, ('B) easy passage of dye throughthe package, (C) no destruction or spoiling of the package as a .resultof its treatment with the pressurized dye, and (D) ease of feeding thedyed yarn directly from the package to looms or-knitting machines.

Basically, two main filament winding methods are known; rotary traversewinding and spindle drive winding. ln'the case of rotary traversewinding, a traversing roll'having a traversing slot on its'surface isused, and the roll contacts the surface of the yarn package. When thethickness of the'wound yarn becomes great, the contact pressure betweenthe roll and package also becomes great. Therefore the winding densityof the yarn differs between the inner and outer portions of the package.Further, variations of winding tightness or hardness occur between bothend portions and the central portion of the package.

When a package formed by the conventional rotary traverse winding isused for package dyeing, the dye tends not to penetrate uniformlythroughout the yarn on the package; uneven dyeing of the yarn occurs.

In the case of the spindle drive winding, there are no defects similarto those in rotary traverse winding, because in spindle drive winding itis easy to control the rate of overfeed of yarn and the magnitude oftension of the feed yarn. But in this case it is difficult to employ awide winding angle; accordingly a layer of yarn is formed in which thewound yarns are positioned almost parallel to each other and in a planewhich is almost perpendicular to the axis of the bobbin. When such apackage. is used for package dyeing, yarn shrinkage tends to destroy thepackage. Therefore, even if a yarn could be dyed uniformly, the packageis not well suited for use directly as a feed yarn package for looms orknitting machines.

OBJECTS OF THE INVENTION It is accordingly an object of this inventionto provide a package which is readily adaptable for package dyeing, inwhich the uniformity of dyeing throughout the package is improved anddyeing is relatively uniform throughout the package, and rewinding isvery easy. Another object is to provide an improved apparatus forproducing such a package, and to provide an efficient and economicalmethod for obtaining such a package as well.

SUMMARY OF THE INVENTION It has nowbeen found that by providing a flyerin such a manner that it is rotatable about an axis that is inclinedwith respect to the axis of the bobbin, and providing a relative axialmovement of the bobbin to the flyer, that the yarn is so laid .into thepackage that it travels continuously inwardly and outwardly toward andaway from the inner and outer peripheries of the yarn portion of thepackage in such a manner that a multiplicity of avenues are provided fordye flow inwardly or outwardly through the package. In this way,uniformity of dyeing in the subsequent dyeing operation is greatlyenhanced.

It has also been found that, because of the very slow axial movement ofthe bobbin that is preferably provided in accordance withthis'invention, and because of the precision with which this movementmay be controlled in connection with the rotation of the angularlyarranged flyer, exceedingly accurate positioning of each yarn isattainable, as each turn of the yarn is arrayed in the actual formationof the package.

These and other objects and advantages of the invention will furtherbecome apparent hereinafter, and in the drawings.

DETAILED'DE SCRIPTION OF THE DRAWINGS tures of this invention;

FIG. 2 represents a sectional view of a typical bobbin produced inaccordance with this invention;

FIG. 3 (i) represents both an end and a side view of a typical bobbinaccording to the prior art;

FIG. 3 (ii) represents top and side views corresponding to those of FIG.3 (i) but showing a typical bobbin prepared in accordance with thisinvention;

FIG. 4 (i) represents a typical end and side view showing the manner inwhich the yarn is arrayed on the package in accordance with theprocedure of the prior art;

FIG. 4 (ii) represents views corresponding to'those of FIG. 4 (i)showing the unique manner in which the yarn is typically laid upon thepackage in accordance with the process of this invention;

FIG. 5 represents a side view of the apparatus in accordance with thisinvention, viewed in a manner similar to FIG. 1, but showing themechanical apparatus for adjusting the inclination of the flyer back andforth;

FIG. 6 represents a front view of the apparatus shown in FIG. 5, showingtwo winding positions and showing the adjusting slots just referred to;

FIG. 7 represents a side view similar to FIG. 5, showing the manner inwhich the thread line is changed by changing the inclination of theflyer axis;

FIG. 8 is a plan view of the apparatus appearing in FIG. 7;

FIG. 9 is a front view of a typical apparatus utilizing features of thisinvention, showing the drive mechanisms for moving the bobbin axiallyduring the winding procedure, and for returning the bobbin to itsinitial position quickly after the winding procedure has been completed;

FIG. 10 represents a view, partially in section, showing a partiallywound bobbin and the thread paths followed in the course of suchwinding;

FIG. 11 represents a partial sectional view, taken along the lay line oftypical yarns within the bobbin, showing the manner in which they arearrayed in the package;

FIG. 12 represents a view, partly in section, showing an adjustableflyer;

FIG. 13 represents an end view showing another form of adjustable flyer;and

FIG. 14 represents a front view of the adjustable flyer appearing inFIG. 13.

Turning now to the specific forms of the invention selected forillustration in the drawings, it will be appreciated that these drawingsand the description of them which follows are not intended to define thescope of the invention, which is defined instead in the claims, but areintended to illustrate preferred ways of carrying the invention intoeffect.

In FIG. 1 a generally vertical shaft 1 supports and drives a rotatingplatform for the bobbin 3 which is intended to have the yarn Y wrappedthereon. The number 2 designates a yarn distributing arm, or flyer,which is mounted to rotate about the axis B. The axis of rotation of theflyer 2 is at an angle to the axis of rotation of the bobbin, 0preferably being an angle within the range from about 2.5 to about 18".As will be observed from the dot-dash line position of the flyer 2,means are provided (not shown in FIG. 1) for shifting the flyer alongthe axis of the bobbin during the winding operation. Either the flyer orthe bobbin, or both, may obviously be moved in order to effect relativemovement between them, in a direction generally along the axis of thebobbin.

The numbers 4, 4 designate bearings supporting rotation of the flyer andthe number designates a pulley for driving the flyer, such pulley beingconnected to a belt and motor of conventional type, not shown.

Preferably, according to this invention, the flyer rotates in thedirection of the arrow B about its axis, while the bobbin rotates in thedirection of the arrow A about its axis; thus the flyer and the bobbincounter-rotate.

The yarn Y is fed through the center 6 of the sleeve 7 upon which thebearings 4, 4' are mounted and passes through the yarn guides 8 and 9onto the package. The radius of the flyer is designated by the letter 1,and the line a-b indicates the diameter of the circular arc described bythe yarn as it moves with the flyer. As is indicated in the drawing, thedistance between point a and point b on the axis of the bobbin is (2)(I) 0 when 0 is the angle of inclination of the flyer axis to the bobbinaxis.

The shape of the yarn package appears in detail in FIG. 2 of thedrawings; it is substantially rectangular in cross-section with inclinedends.

FIG. 3 (i) shows a typical yarn package which is wound up in successivelayers in accordance with the prior art. In contrast, FIG. 3 (ii) showsa package prepared in accordance with this invention.

As will appear in FIG. 4 (i) the yarn in the prior art process referredto is wound in a relatively cylindrical manner; the yarn travels at asubstantially constant diameter during each passage of 360 around theaxis of the bobbin and the yarn is laid thereby in a helical path backand forth, always at substantially the same diameter. By way ofcontrast, as is apparent in FIG. 5 (ii) assuming the yarn begins atpoint 40 at the outer periphery of the package, it moves not onlygenerally helically around the package but also inwardly toward theinner periphery of the yarn portion of the package, traveling betweenouter diameter D and inner diameter d passing successively through thepoints 41, 42 and 43. Then the yarn immediately begins to move along aline of increasing diameter as indicated by the line running from points43 to 44 and then on to points 45 and 46, at which time the maximumdiameter has again been attained. This procedure continues with greatfrequency throughout the entire package winding operation and isinstrumental in attaining the important advantages heretofore referredto. Since the yarn travels continuously back and forth between theinnermost diameter and the outermost diameter, greatly improved packagedyeability is achieved.

FIGS. 5 and 6 show a specific means for inclining the flyer with respectto the bobbin and for maintaining the flyer in an adjusted inclinedposition. In the drawing, the number 3 designates the bobbin and thenumber I designates the rotating platform on which it is mounted; 2designates the flyer as heretofore discussed. It will be appreciatedthat means are provided for rotating the shaft 11 in such a manner thatthe bobbin supporting plate 10 is very slowly moved along the bobbinaxis in a constant direction. The number 12 designates a supportingblock for a slotted block 13 having a curved upper surface as appears inFIG. 5. A plate 17 fits on top of the slot 14, and a bolt 15 is providedwith an adjusting nut travels within the slot 14. A supporting head 16for the flyers is mounted on top of the plate 17 and, as will beapparent, can be maintained in any desired adjusted inclined position byadjusting and tightening the screws 15 as will be apparent particularlyfrom FIG. 5.

FIG. 7 shows the manner in which the thread line is changed by changingthe inclination of the flyer axis. It has been found that a gentlechange of angle of the thread line gives a much lower tension in theyarn than a sharp angle, and is to be preferred in accordance with thisinvention. This shows a further advantage of the inclination of theflyer in accordance with this invention. The number 19 designates thesupply package for the yarn which is to be wound upon the bobbin 3; itis mounted on a supporting rod 20 held by an arm 21 and clamp 22. Thethread line through the guide 18 shows the angle that is obtained by avery small inclination of the flyer with respect to the bobbin axis,while the thread line through the guide 18' shows the relatively gentleangle of change of the yarn path that is achieved by a relatively largeangle 6 between the flyer axis and the bobbin axis. This relativelygentle angle, as stated, provides for a much lesser tension and assistsin producing a superior package.

FIG. 8 is a plan view of the apparatus and of the angles appearing inFIG. 7 and further illustrates this advantageous relationship.

Referring now to FIG. 9 of the drawings, this is a front view showingtwo different motors for driving the bobbin; one for the windingoperation and one for quickly returning the completed bobbin to itsinitial position after the winding of the package has been completed.The motor 26 is connected to operate through a clutch 27 and a speedreducer 28 to drive the shaft 11 to raise the base plate 10 very slowly.In accordance with the illustrated embodiment of the invention, theflyer 2 is caused to rotate in a fixed position. Thus, in accordancewith this embodiment, the base plate 10 is moved in a constant directionand upon completion of this movement the winding has been completed.FIG. 9 also shows another motor 23 connected through a clutch 24 andhigh speed driving transmission 25, which is automatically connected,using conventional limit switches and relays, to de-energize the motor26 and to energize the motor 23 at the conclusion of the windingoperation to bring the base plate 10 down very quickly, in preparationfor a change of bobbins. Thus, when the limit switch (not shown) sensesthe fact that the base plate 10 has reached its uppermost position shownin dotted lines in FIG. 9, the clutch 27 is disengaged and the clutch 24is engaged; also the motor 26 is disengaged and the motor. 23 isengaged. This brings the bobbin down quickly to its initial position andena bles the operator to make a rapid change, replacing the full bobbinwith an empty bobbin sleeve.

FIG. 10 shows the nature of a partially completed package when processedin accordance with the showing of FIG. 9. The dash lines show the nextcourse of yarn as it is to be laid upon the package.

FIG. 11 shows in detail the general manner in which typical portions ofyarn extend from outside to inside and from inside to outside. Thesecreate excellent passages as indicated by the arrows in FIG. 11, for thecomplete penetration and permeation of the package with dye, when thepackage is later used in a package dyeing operation.

FIG. 12 shows an adjustable form of flyer member 47, 48 and 50 whereinthe yarn distributing member 50 can be located at any one of a varietyof diameters. As shown, the flyer arm 50 and its correspondingcounterbalancing element shown at the right side of the figure arelocated at the maximum diameter. However they may be located atintermediate diameter positions by simply reinserting them into theholes 49 or other holes provided for the purpose.

FIGS. 13 and 14 show similar arrangements using a head 47 for the flyermember 48', 50 and for its corresponding counterbalancing element,together with the use of bores 51, 52 and set screws 53 for securingthese members in any desired adjusted position. millimeter The followingexamples are illustrative of the invention:

EXAMPLE 1 110 denier, 36 filament nylon yarn was wound, using a winderof this invention under the following conditions:

Inclination between spindle rotational axis and flycr rotational axis 6Spindle RPM 600 RPM Flyer RPM (in opposite direction to spindle) 250 RPMBobbin axial movement 4 mm/min Outer diameter of bobbin mm Height ofbobbin 180 mm Winding tension 15 g *millimeter The wound package wasdyed using a dye liquid containing 2.0 percent of Nylomlne Red 2 BS, 2.0percent of Lyogen-P and 1.5 percent of acetic acid (concentra tion 99percent), and under such conditions that the temperature of the dyeliquid is controlled at first at normal temperature, and raised to 100 Cand maintained at 100 C for 60 minutes, then cooled.

A perforated bobbin was used and the dye was fed from the inside of thebobbin toward the outside.

No deformation of the package was observed and uniform dyeing wasobtained. It was easily possible to feed the yarn to a loom or knittingmachine at 400 m/min. meter) EXAMPLE 2 A 40-denier two-ply spunpolyester yarn was wound on a winder of this invention under thefollowing conditions:

Inclination between spindle rotational axis and flyer The resultingpackage was dyed with dye liquid containing 2.0 percent Resoline BlueFBL and 1.0 percent Sun Solt No. 1200, under such conditions that thetemperature of the dye liquid was at first controlled at 60 C and thenraised to C and maintained at 120 C for 60 minutes, and after thatcooled.

A perforated bobbin was used and the ,dye was fed reciprocally for 4minutes from the inside toward the outside, and then for 6 minutes fromoutside to inside.

After dyeing, the package was treated by reduction for 20 minutes, at 30C with a liquid containing 1 g/l of caustic alkali, 1 g/l of an alkalimetal salt of hydrosulfite and 2 g/l of amylazine.

No deformation of the package was observed, and dyeing was uniform.Feeding the yarn to a machine at 400 m/min was easily accomplished.

EXAMPLE 3 75 denier, 36 filament polyester yarn, bulked up by falsetwisting, was wound on a winder of this invention under the followingconditions:

Inclination between spindle rotational axis and flyer The package wassteamed at 85 C for 20 minutes and dyed with a liquid containing 1.5percent of Resoline Red PB, and 1.0 percent of Sun Solt No. 1200; thetemperature of the dye liquid was controlled at first at 60 C, andraised to 125 C and maintained at 125 C for 60 minutes and after thatcooled.

A perforated bobbin was used and the dye was fed from inside the bobbinto the outside.

No deformation of the package was observed and uniform dyeing wasobtained. Further, the yarn was easily fed at 250 m/min.

EXAMPLE 4 A bulked two-ply 48 denier spun acrylic yarn was wound on awinder of this invention under the following conditions:

Inclination between spindle rotational axis and flyer The package wassteamed at 100 C for 30 minutes at -600 mm Hg in an autoclave and dyedwith a dye liquid containing 2.0 percent of Catilon Blue NBLH, 1.5percent of Sumiacryl Yellow 36, 1.0 percent of Catiogen L, acetic acid(concentration 99 percent) and sodium acetate. The temperature of thedye liquid is controlled at first at 60 C, and raised to 100 C andmaintained at 100 C for 60 minutes, and after that cooled to 60 C in 40minutes.

A perforated bobbin was used and the dye was fed from inside the bobbinto the outside.

No deformation of package was observed and uniform dyeing was obtained.Further, feeding of the yarn at 250 m/min was accomplished.

The following is claimed:

1. A yarn winding apparatus for producing an annular package offilamentary yarn, said apparatus comprising:

a. a spindle mounted for rotary motion about its axis;

b. yarn guide means mounted adjacent the spindle for circular rotatingmotion in a plane inclined from about 2.5 to about 18 from a planeperpendicular to the rotational axis of the spindle;

c. means for effecting relative bodily movement between the inclinedplane of the yarn guide and the spindle in the longitudinal direction ofthe spindle axis at a rate of movement which is slow relative to therotational speeds of said spindle and yarn guide means;

d. said yarn guide means including a flyer mounted on a rotational shaftthe axis of which is inclined from about 2.5 to about 18 from therotational axis of said spindle; and

e. means for effecting rotation of the flyer and rotation of the spindlein opposite directions.

2. Apparatus as defined in claim 1, further comprising means foradjusting the angle between the rotational axis of the flyer and therotational axis of the spindle.

3. Apparatus as defined in claim 1, further comprising means effectiveupon completing the winding of a package for quickly returning thespindle bodily to its initial position.

4. Apparatus as defined in claim 1, further comprising means foradjusting the rotational radius of the flyer.

5. Apparatus according to claim 1 wherein said means for effectingrotation of the flyer and rotation of the spindle in opposite directionsincludes means for effecting rotation of the flyer and rotation of thespindle in opposite directions at different rotational speeds.

6. Apparatus according to claim 5 wherein the means for effectingrotation of the flyer and spindle in opposite directions at differentspeeds includes means for driving the spindle at a rotational speedsubstantially higher than that of the flyer.

7. An annular package of continuous filamentary yarn wound on a bobbin,said winding being characterized by:

a. a succession of helical turns of substantially 360 each;

b. each turn traverses a predetermined short length in the axialdirection of the bobbin, said length being much shorter than the totalaxial length of the bobbin;

c. the yarn in each turn is displaced from the center axis of the bobbinby a plurality of radial dimensions.

8. In a method of winding yarn upon a bobbin sleeve,

the steps which comprise:

a. moving the yarn angularly about the bobbin sleeve in a plane inclinedfrom between 2.5 and 18 relative to a plane normal to the axis of thebobbin sleeve to create a turn of yarn at a given location about thesleeve, said turn occupying a short axial distance relative to the totalaxial length of the sleeve;

b. rotating said sleeve about its axis at a speed higher than that atwhich said yarn is moved angularly about the bobbin sleeve;

c. repeating the steps of (a) and (b) while slowly displacing therotating bobbin in its axial direction, whereby individual yarn turnsare displaced by different radial distances from the axis of the sleeve.

9. The method of claim 8 characterized by rotating said sleeve in adirection of rotation which is opposite to the direction of movement ofthe yarn.

l t I. i

1. A yarn winding apparatus for producing an annular package offilamentary yarn, said apparatus comprising: a. a spindle mounted forrotary motion about its axis; b. yarn guide means mounted adjacent thespindle for circular rotating motion in a plane inclined from about 2.5*to about 18* from a plane perpendicular to the rotational axis of thespindle; c. means for effecting relative bodily movement between theinclined plane of the yarn guide and the spindle in the longitudinaldirection of the spindle axis at a rate of movement which is slowrelative to the rotational speeds of said spindle and yarn guide means;d. said yarn guide means including a flyer mounted on a rotational shaftthe axis of which is incliNed from about 2.5* to about 18* from therotational axis of said spindle; and e. means for effecting rotation ofthe flyer and rotation of the spindle in opposite directions. 2.Apparatus as defined in claim 1, further comprising means for adjustingthe angle between the rotational axis of the flyer and the rotationalaxis of the spindle.
 3. Apparatus as defined in claim 1, furthercomprising means effective upon completing the winding of a package forquickly returning the spindle bodily to its initial position. 4.Apparatus as defined in claim 1, further comprising means for adjustingthe rotational radius of the flyer.
 5. Apparatus according to claim 1wherein said means for effecting rotation of the flyer and rotation ofthe spindle in opposite directions includes means for effecting rotationof the flyer and rotation of the spindle in opposite directions atdifferent rotational speeds.
 6. Apparatus according to claim 5 whereinthe means for effecting rotation of the flyer and spindle in oppositedirections at different speeds includes means for driving the spindle ata rotational speed substantially higher than that of the flyer.
 7. Anannular package of continuous filamentary yarn wound on a bobbin, saidwinding being characterized by: a. a succession of helical turns ofsubstantially 360* each; b. each turn traverses a predetermined shortlength in the axial direction of the bobbin, said length being muchshorter than the total axial length of the bobbin; c. the yarn in eachturn is displaced from the center axis of the bobbin by a plurality ofradial dimensions.
 8. In a method of winding yarn upon a bobbin sleeve,the steps which comprise: a. moving the yarn angularly about the bobbinsleeve in a plane inclined from between 2.5* and 18* relative to a planenormal to the axis of the bobbin sleeve to create a turn of yarn at agiven location about the sleeve, said turn occupying a short axialdistance relative to the total axial length of the sleeve; b. rotatingsaid sleeve about its axis at a speed higher than that at which saidyarn is moved angularly about the bobbin sleeve; c. repeating the stepsof (a) and (b) while slowly displacing the rotating bobbin in its axialdirection, whereby individual yarn turns are displaced by differentradial distances from the axis of the sleeve.
 9. The method of claim 8characterized by rotating said sleeve in a direction of rotation whichis opposite to the direction of movement of the yarn.